HEAT-SEALABLE POLYSTYRENE-BASED BLENDS

Abstract: A sealable, thermoplastic molding composition which can be employed to seal dairy food containers, comprising from 20 to 60 percent by weight of an optionally rubber-reinforced styrenic resin; from 30 to 70 percent of a styrene-butadiene-styrene block copolymer; and from 4 to 40 percent of a copolymer of ethylene and acrylic acid.

Description: HEAT-5EALABLE POLYSTYRENE-BASED BLENDS The present invention relates to styrenic resin compositions More specifically, the invention relates to styrenic resin compositions which are heat-sealable The dairy industry commonly uses aluminum foil with a hot melt seal lacquer as a lid or sealing structure for many types of plastic containers, such as cups for yogurt and other dairy products Since aluminum can resist high temperatures, the cycle time for sealing the lid to the container can be kept short Unfortunately, the tear resistance of aluminum lids is not always sufficient, thereby resulting in tearing of the lid during peeling Lids prepared using polyvinyl chloride (PVC) or polyesters, such as PET, are also common in the marketplace These plastic lids typically employ hot melt coatings to ensure adhesion to the container The hot melt coatings melt at a temperature lower than the temperature at which the plastic top layer begins to deform or melt and stick to the seal bar A second type of plastic lid commonly found in the marketplace includes one or more polystyrene-compatible resin layers with one or more polyester top or substrate layers coextruded with the polystyrene-compatible resin layer to improve the strength of the lid, and to prevent the hot-seal bar from sticking to the lid A disadvantage of lidding systems employing PVC or polyesters is that these systems contain polymers which are not fully compatible with the polystyrene commonly employed in the container to which the lidding system is attached Therefore, recycling of dairy containers containing diverse polymeric materials requires a preliminary, expensive separation step The above-described plastic lid materials are not fully compatible for recycling purposes with polystyrene dairy containers It would be desirable to have an easily sealed plastic lidding system for thermoformed food containers that peels off easily, while retaining its physical integrity Integrity is important in the case of food packaging in order to guarantee the shelf life of the packaged food Additionally, it would be desirable to have a lidding system which is completely compatible with the polystyrene dairy container material, thereby allowing easy recyclabi ty of container and lid without the need for expensive separation steps It would be further desirable in the dairy food packaging market to have a composition which would provide a controllable, peelable, adhesive seal after conventional heat sealing processes, which typically last from between 0 5 to 2 seconds, and which would display minimal changes in adhesion force between container and lid with seal bar temperature variations of up to 15°C Further, it would be desirable if the sealing layer would soften, melt and stick to the container before the lid deforms significantly The present invention includes such a composition which can be employed to seal dairy food containers without the foregoing disadvantages, the composition comprising from 20 to 60 percent by weight of an optionally rubber-reinforced styrenic resin, from 30 to 70 percent of a styrene-butadiene-styrene block copolymer, and from 4 to 40 percent of a coDOiymer of ethylene and acrylic acid Additionally, the invention includes an article which can be used as a lid for dairy containers, the article comprising a layer of an optionally rubber- -reinforced styrenic resin; and a layer comprising an ethylene-acry c acid copolymer, an optionally rubber-reinforced styrenic resin, and a styrene-butadiene-styrene block copolymer Advantageously, the composition and lid of the present invention are highly compatible for recycling with styrenic resins, such as polystyrene found for example, in dairy food containers, and are easily peelable with simultaneous high resistance to tearing. The composition of the invention comprises an optionally rubber-reinforced styrenic resin, a styrene-butadiene-styrene block copolymer, and a copolymer of ethylene and acrylic acid. The composition of the invention comprises the optionally rubber reinforced styrenic resin in an amount which can be at least 20, can be at least 33, can be at least 40 and can be at least 45 weight percent based on the weight of the composition The composition can have less than 60, and can have less than 55 weight percent of the optionally rubber- reinforced styrenic resin PreferaDly, tne composition of the invention comprises from 40 to 60 weight percent of the styrenic resin, and more preferably from 45 to 55 percent. Preferably, the styrenic resin is a rubber-modified, or high impact, styrenic resin. The optionally rubber-reinforced styrenic resins are well-known to those skilled in the art, are widely available commercially, and can be prepared by any of the several polymerization methods known to those skilled in the art including, for example anionic, catioπic or free radical, which is preferred, polymerization. The rubber-modified polymers can be prepared by well-known methods including, for example, mass, emulsion, suspension and mass suspension methods. Mass polymerization is preferred. In general, continuous methods are employed for polymerizing the monovmyl aromatic compound. The optionally rubber-reinforced styrenic resins of the present invention are polymers of one or more monovmyl aromatic compounds. Representative monovmyl aromatic compounds include styrene; alkyl substituted styrenes such as alpha-alkyl-styrenes (for example, alpha-methylstyrene and alpha-ethyl styrene) and ring alkylated styrenes and isomers thereof (for example, ortho-ethylstyrene, 2,4-dιmethyl styrene and vinyltoluene, particularly, ortho or para vinyl toluene); ring substituted halo-styrenes such as chloro-styrene, 2,4-dichloro- styrene; and styrenes substituted with both a halo and alkyl group such as 2-chloro-4- -methylstyrene; and vinyl anthracene. In general, the preferred monovmyl aromatic monomers are styrene, alpha-methylstyrene, one or more of the vinyltoluene isomers, and/or mixtures of two or more of these, with styrene being the most preferred monovmyl aromatic compound. The monomer may optionally comprise minor amounts of one or more additional comonomers, preferably in an amount less than 10 percent by weight of the polymerizable monomer mixture. Suitable comonomers are unsaturated nitπles, for example acrylonitπle; alkyl acrylates and alkyl methacrylates, for examσle metnyl metnacrylate or n-Dutylacrylate, ethylenically unsaturated carboxy c acid monomers, and ethylenically unsaturated carboxy c acid derivative monomers including anhydrides and amides such as maleic anhydride, and maleimides such as N-phenyl maleimtde The styrenic resin optionally is rubber-modified The rubbers preferably employed are those polymers and copolymers which exhibit a second order transition temperature which is not higher than 0°C, preferably not higher than -20°C, and more preferably not higher than -40°C as determined or approximated using conventional techniques, for example, ASTM Test Method D-746-52 T. Unsaturated rubbers are more preferred Highly preferred rubbers are alkadiene polymers Suitable alkadienes are 1 ,3-conjugated dienes such as butadiene, isoprene, chloroprene or piperylene Most preferred are homopolymers (excepting any coupling monomers) prepared from 1 ,3-conjugated dienes, with such homopolymers of 1 ,3-butadιene being especially preferred Alkadiene copolymer rubbers containing small amounts, for example less than 15, preferably less than 10 weight percent, of other monomers such as monovmyl aromatics can also be employed The rubber is advantageously employed in amounts such that the rubber- reinforced styrenic resin contains from 2 to 20 percent, preferably from 3 to 17 percent, more preferably 3 to 15 weight percent rubber or rubber equivalent The term " rubber" or "rubber equivalent" as used herein to indicate weight amounts of rubber material is intended to mean, for a rubber homopolymer (such as polybutadiene), simply the amount of rubber, and for a block copolymer, the amount of the copolymer made up from monomer(s) which, when homopolymeπzed form a rubbery polymer. For example, for calculating the amount of rubber in a composition where a butadiene- -styrene block copolymer rubber has been employed, the "rubber" or "rubber equivalent" of the composition is calculated based on only the butadiene component in the block copolymer Obviously where physical properties or other aspects of the rubber material are measured, the complete rubber material including any comonomers is referred to Styrene-butadiene-styrene (SBS) block copolymers are also well-known to those skilled in the art and are widely available in commerce The SBS block copolymer suitably contains from 10 to 50 percent styrene by weight, preferably from 20 to 45 percent styrene Examples of suitable SBS block copolymers include TUFPRENE A, available from Asahi Chemical Industry Company Ltd , FINAPRENE 414, available from The Petrofina Group, and VECTOR 6241- D, available from Dexco Polymers The composition of the invention comprises the SBS block copolymer in an amount which can be at least 30, can be at least 33, and can be at least 35 weight percent of the composition The composition comprises the SBS block copolymer in an amount which can be less than 70, can be less than 55, can be less than 50 and can be less than 45 weight percent based on the weight of the composition Preferably, the composition of the invention comprises from 35 to 55 weight percent of the SBS block coDolymer, and more øreferaoly from 33 to 45 percent of the SBS block copolymer Preferably, the SBS block copolymer is rubbery Copolymers of ethylene and acrylic acid are well-known to those skilled in the art and are commonly available commercially The composition of the present invention advantageously includes from 4 to 40 weight percent of the ethylene acrylic acid (EAA) copolymer, preferably contains from 5 to 15 percent of the EAA copolymer, and more preferably contains from 8 to 12 percent EAA copolymer. The EAA copolymer suitably contains from 6 to 12 weight percent of acrylic acid units, and preferably contains from 8 to 10 percent of acrylic acid units. Examples of suitable EAA copolymers include PRIMACOR 1410 and PRIMACOR 1420R, which are available from The Dow Chemical Company The composition of the invention is conveniently obtained by blending the styrenic resin, the SBS block copolymer and the EAA copolymer using any of the techniques known to those skilled in the art for preparing polymer blends. Melt blending, such as by extrusion, is an example of a preferred method of preparation. The blended composition may also contain additives such as pigments, plasticizers or lubricants such as mineral oil, butyl stearate or dioctyl phthalate; stabilizers, including antioxidants (for example, alkylated phenols such as di-tert-butyl-p-cresol or phosphites such as tπsnonyl phenyl phosphite); and mold release agents, for example, zinc stearate. The composition of the invention is useful as a heat sealable adhesive, and can be employed as a sealing layer together with a carrier or structural support layer. Accordingly, the invention includes articles, such as films, foils or sheets, which contain a heat-sealable layer, or sealing layer, prepared from the composition of the invention and a styrenic resin-containing support layer. The support layer and the heat-sealable layer can be joined via techniques well-known to those skilled in the art such as, for example, coextrusion or lamination. Advantageously, no glue layer is required to join the support layer to the heat-sealable layer. Examples of materials suitable for use as the support include thermoplastics such as styrenic resins, such as polystyrene and high impact polystyrene, styrene-butadiene block copolymers, and mixtures of these materials. The material of the support layer should be compatible with the sealing layer composition and should have good physical properties. In general, in the case where the article of the invention is a thin sheet, or foil, which is to be used to make lids for containers, such as dairy food containers, the composition of the support layer depends upon the physical properties desired in the final lidding foil. The seal layer composition can be included in the support layer to provide for sufficient compatibility of the sealing layer to the support layer. Compatibility is important during peeling of the lid from the container. The amount of seal layer composition in the support layer preferably is at least about 30 weight percent, and more preferably is from 32 to 40 percent. The heat-sealable, peelable lidding structure of the invention is obtained by comoining the support layer and the sealing layer as described hereinabove The thickness of the final lidding structure depends upon the physical properties that are required and the market requirements, incluαing the processing behavior of the lids in food packaging macnines Lidding structures advantageously are from 60 to 350 μm thick, but thicker or thinner structures can be employed Preferably, the structures are from 80 to 300 micron thick Generally speaking, the seal layer is minimally about 5 percent of the total lidding structure thickness, and preferably is from 7 to 20 percent of the total thickness Preferably, the lidding structures of the invention include a top layer material, such as an ink and/or a lacquer coating, for the purpose of preventing the seal bar of a heat- sealing machine from sticking to the support layer of the lidding material In this embodiment, the support layer is between the top layer and the seal layer The lidding structures of the invention can be sealed using any conventional heat- -sealmg or impulse sealing machines which are commonly used for styrene polymer cups As is well-known to those skilled in the art, settings for sealing machines are determined by the temperature of the seal bar, pressure of the seal bar applied to the πm of the containers, the seal time, and the thickness of the lidding structure Advantageous sealing conditions are at temperatures between 120°C and 220°C, pressures between 1 and 10 bar, and seal times between 0 5 and 1 5 seconds Preferably, the seal bar temperature is between 160°C and 200°C, tπe seal pressure is between 4 and 7 bar, and the seal time is between 0 7 and 1 2 seconds The composition of the invention can be employed to prepare lids which exhibit a very reproducible, soft, peeling behavior The composition provides an improved temperature range for sealing, that is, acceptable peel strength values are obtainable over a wider temperature range using the composition of the invention as a sealing layer The force necessary for separating the container and the lid can be defined as peel strength Peel strength values depend on many variable factors, but values between 80 and 450 grams per 3 millimeter width of heat-seal area, via a peeling movement in the length direction of the seal, are found to permit easy peelability at a given peel test temperature, peel speed and peel angle For the purposes of the present invention, the term "peelability" means that the lidding structure and the containerto which it is sealed can be manually separated without destruction of the container or the lid and without leaving parts of the seal layer resin on the rim of the container after peeling of the lid occurs The following experiments are set forth to illustrate the present invention and should not be construed to limit its scope All parts and percentages are by weight and ail temperatures are in degrees Celsius unless otherwise indicated Coextrusion Lidding toil from which individual lids can be stamped or cut, is prepared by coextrusion of a suDport laver and a sealing layer The seal layer composition is prepared in a first extruder and the mam support layer composition is prepared in a second extruder, both operating under normal extrusion conditions tor polystyrene such that the compositions leave the extruders at temperatures in the range of from 195°C to 198°C The two compositions are fed directly from the extruders to a coextrusion feedblock to make coextruded films wherein the seal layer constitutes 10 percent of the total thickness Compositions of the main (m), or layer support, and the sealing (s) layer are given in Table 1 The pigment is in the main layer only and is a 50/50 blend of polystyrene and a white colorant consisting ' predominantly of Tι0 The compositions are prepared from the following set of materials the styrenic resin is STYRON 472, which is a high impact polystyrene available from The Dow Chemical Company; the EAA is PRIMACOR 1410 which is available from The Dow Chemical Company, and the SBS is TUFPRENE A, which is available from Asahi Chemical Industry Co Ltd Table 1 : Compos itions Styrenic Composition EAA nt resin SBS Pigme 1 (m) 70 10 20 - 1 (s) 50 10 40 - 2 (m) 80 20 6.67 2 (s) 50 10 40 3 (m) 80 20 6.67 3 (s) 20 40 40 Peel Strength Testing after Heat Sealing The peeling strength of the lidding foil are determined by measuring the strength of a heat-sealed bond between the sealing layer of the coextruded lidding foil and a 1 mm thick base of rigid polystyrene, which represents the dairy container to which the lidding foil will be sealed The resin for the rigid polystyrene base layer to which the lidding foil is adhered is STYRON 472 An SGPE 20 KOPP heat sealing machine is employed to generate a seal of 3 millimeters by 100 millimeters using a seal time of 1 second, a seal bar pressure of 7 bar, and various seal bar temperatures For seal bar temperatures of 180°C and 220°C a seal time of 0 5 seconds is also employed A foil of polytetrafluoroethylene is employed between the seal bar and the lidding foil The peel strengtn of the test samples is measureα using the method of ISO 8510- 1 : 1990 using a 90° angιe. Test samples are allowed to cool for at least 10 minutes before peeling Peeling is conducted in the direction of the length of the test strips. The heat-sealed test samples are peeled at a constant speed of 100 _+_ 5 millimeters per minute. The average peel force in grams per width of seal is determined based upon at least 3 samples. In addition to peel strength, tearing of the lidding foil is reported. The test results are summarized in Table 2. Table 2: Peel Strength (in grams) as a Function of Temperature Thick¬ Sealer- Sealer- Sealer- Sealer- Sealer- Sealer- Sealer- Sealer- Sealer- Comp'n ness setting setting setting setting setting setting setting setting setting (μm) 120°C 130°C 140°C 150°C 160°C 170°C 180°C 200°C 220 U C 1 100 10 20-40 60-80 (VR) 60-80 (VR) 160 (VR) 160-180 (R) 200 (VR) 300-400 T (VR) 120 (0.5 sec) 2 210 < 10 < 10 < 10 50 (R) 50 (R) 80 (VR) 100 (VR) 160 (VR) 210 20 (0.5 sec) 100 (0.5 sec) 3 100 10 10 25 (VR) 40 (VR) 40 (VR) 60 (VR) 60-100 80- 100 100 (VR) I 00 40 (0.5 sec) (VR) 90 (0.5 sec) I VR = very reproducible R = reproducible T = tearing As can be seen from Table 1 , the addition of white pigment has little effect on the sealing behavior of lidding structures Compare Composition 1 to Composition 2 Very reproducible, constant peeling forces over a wide seal bar temperature range are observed for Compositions 1 , 2 and 3 without tearing PRIMACOR 1410 need not be employed in the sαpport or main layer The data indicates that seal times of 0 5 seconds are feasible; this is significant as this seal time is towards the low end of the range of seal times employed with aluminum lids. Accordingly, the lids of the invention can be employed as a replacement for aluminum lids.

Claims: z l?ιi m^ * 1 A composition comprising- trom 20 to 60 percent by weight of an optionally rubber-reinforced styrenic resin; from 30 to 70 percent of a styrene-Dutadiene-styrene block copolymer; and from 4 to 40 percent of a copolymer of ethylene and acrylic acid 2 The composition of Claim 1 comprising from 45 to 55 percent of the styrenic resin 3 The composition of Claim 1 wherein the styrenic resin is rubber-reinforced 4 The composition of Claim 1 wherein the styrenic resin is not rubber-reinforced 5 The composition of Claim 1 wherein from 33 to 55 percent of a styrene- butadiene-styrene block copolymer is employed 0 6 The composition of Claim 1 wherein the styrene-butadiene-styrene block copolymer comprises from 10 to 50 percent styrene units 7. The composition of Claim 1 comprising from 5 to 15 percent of the copolymer of ethylene and acrylic acid 8 The composition of Claim 1 wherein the copolymer of ethylene and acrylic acid 5 comprises from 6 to 12 percent acrylic acid 9 A heat-sealable composite, comprising a heat-sealable layer comprising the composition of Claim 1 , and a support layer of an optionally rubber-reinforced styrenic resin. 10. A composition comprising: from 45 to 55 percent by weight of a rubber- reinforced styrenic resin; from 33 to 55 percent by weight of a styrene-butadiene-styrene block 0 copolymer having from 10 to 50 percent styrene units; and from 5 to 15 percent by weight of an ethylene acrylic acid copolymer. 5 0 5

Inventors: ANTHEUNISSE CORNELIS, ANTHEUNISSE, CORNELIS
Applicants: DOW CHEMICAL CO, THE DOW CHEMICAL COMPANY
Application year: 1994
Main classification: C08L25
IPC codes: B32B25, C08L23, C08L25, C08L33, C08L51, C08L53